ZS TD project

[ZS Phil]

Hi all, thought I'd share with you guys.

You may have seen my threads over on .org where there is a big diesel community but figured although its not a v6 or yellow some of you may still appreciate it.

So, Ive had my current ZS for three years now and over that time its evolved into something pretty unique I think.
Ill just talk about the latest episode of modifaction here...

I took it off the road in Feb this year and got an awesome little clio 172 to drive round in while the ZS was under way. The Clio was sold at the end of summer and the ZS is now back on the road and better than ever. I do miss the Clio and would suggest that if you havnt tried one to do so at some point.

Anyway, back to the MG...

All this was brought about because back in February when I took it off the road the standard clutch couldn't cope with the torque from the VNT (didnt help that the release arm had seized), one of the exhaust valve seals began to leak so it was burning oil and I had an LSD gearbox to fit along with a CG stage three clutch from dark ice designs.

It was originally the plan just to do the work described above but being a perfectionist I went a whole lot further as the following pictures show...

[ZS Phil]

And the dissasembly began...

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/2013-07-16185448_zpsd99bdbd5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/2013-07-16185448_zpsd99bdbd5.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08185946_zps45c0bb3f.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08185946_zps45c0bb3f.jpg.html)

The piston which had been recieving oil from the leaky oil seal:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08190056_zpsffbd1153.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08190056_zpsffbd1153.jpg.html)

And the leaky oil seal evidence:
Normal
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08190335_zps4a532564.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08190335_zps4a532564.jpg.html)
Leaky
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08190316_zpsdc1b1df8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08190316_zpsdc1b1df8.jpg.html)

Stripping the head:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08193452_zps37f95e3b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08193452_zps37f95e3b.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08212459_zps9b2d23ab.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08212459_zps9b2d23ab.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08212517_zps0f5739b8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08212517_zps0f5739b8.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-08212554_zps96ca37f5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-08212554_zps96ca37f5.jpg.html)

Aftermath of cleaning the head and the plenum/ charge pipe
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-14192500_zps0c67d81b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-14192500_zps0c67d81b.jpg.html)

Valves, cleaned vs how they were:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-14204117_zps71e01baa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-14204117_zps71e01baa.jpg.html)

Thought I might as well "lap them in". They didnt really need it but one or two were getting a tiny bit pitted so kept me busy for a few hours until they were all perfect:
Old school...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-14220750_zpsa3bdcfc2.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-14220750_zpsa3bdcfc2.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15194104_zps5a1ccac5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15194104_zps5a1ccac5.jpg.html)

[ZS Phil]

Genuine new goodness, oil seals and head bolts
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15194308_zpsc2da6755.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15194308_zpsc2da6755.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15194417_zpsac9963d6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15194417_zpsac9963d6.jpg.html)

Had to modify my valve remover as the L has a deep head:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15195111_zpscd44a05a.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15195111_zpscd44a05a.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15195102_zps0f9cbd35.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15195102_zps0f9cbd35.jpg.html)

Going back together
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15205540_zps93a0bf35.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15205540_zps93a0bf35.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15212757_zpsc4a9109a.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15212757_zpsc4a9109a.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15214628_zps44bf61ec.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15214628_zps44bf61ec.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15222013_zps00b5dafb.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15222013_zps00b5dafb.jpg.html)
Shiney :D
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-15222138_zps56c76491.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-15222138_zps56c76491.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16190953_zps2bc22c42.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16190953_zps2bc22c42.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16203002_zps021bf165.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16203002_zps021bf165.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16203905_zps30bfb53c.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16203905_zps30bfb53c.jpg.html)

New HG, only the best...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16204057_zps7121a4a3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16204057_zps7121a4a3.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16204251_zps90c48a9e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16204251_zps90c48a9e.jpg.html)

New vs old head bolts. Old ones were still good but wanted everything spot on:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16205316_zpsac9ff1db.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16205316_zpsac9ff1db.jpg.html)

Working 8 till late...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-16220020_zpsb5c8ac98.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-16220020_zpsb5c8ac98.jpg.html)

Belts back on
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-17185715_zpse1a997ad.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-17185715_zpse1a997ad.jpg.html)

Inectors primed and hoses back on
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-17210658_zpsa0e356c6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-17210658_zpsa0e356c6.jpg.html)

Why have mild?
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-26160237_zpsee04d87f.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-26160237_zpsee04d87f.jpg.html)

When you can have stainless:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-07-26160724_zpsafc95558.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-07-26160724_zpsafc95558.jpg.html)

New leak off pipe of course
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20head/2013-08-08144848_zps5c27a73b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20head/2013-08-08144848_zps5c27a73b.jpg.html)

New glow plugs, Bosch
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-07-16153628_zps8a05f935.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-07-16153628_zps8a05f935.jpg.html)

[ZS Phil]

Other new stuff:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-07-02133759_zps4afc53a6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-07-02133759_zps4afc53a6.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-07-02134233_zpseb532de9.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-07-02134233_zpseb532de9.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-07-02134305_zps7e524b91.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-07-02134305_zps7e524b91.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-07-16153301_zpsc4740e19.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-07-16153301_zpsc4740e19.jpg.html)

Next on the to do list was the gearbox and clutch:
CG stage 3...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22215556_zps1ec0d30e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22215556_zps1ec0d30e.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212532_zps36c72bb3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212532_zps36c72bb3.jpg.html)
Old vs New
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212413_zpsf754218d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212413_zpsf754218d.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212216_zpsa86922b2.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-22212216_zpsa86922b2.jpg.html)

Gearbox old vs new, new one is steel caged and has Torsen type B LSD as the pict show:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23204501_zps5eed1ef7.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23204501_zps5eed1ef7.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23205913_zpsaad2cfe1.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23205913_zpsaad2cfe1.jpg.html)

After a good clean. It was taken from a 25 (Catteralls) so had to swop the release arms and mounts over. They took a lot of cleaning up and a lot of greasing!
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23215745_zps2464841b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23215745_zps2464841b.jpg.html)

Flywheel pre skimming
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23230855_zpsa3342766.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23230855_zpsa3342766.jpg.html)
Check out the glazing
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23230917_zpscbed7745.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-06-23230917_zpscbed7745.jpg.html)

And after skimming, they took out the dowels and did a great job:
removing the protective film
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01185527_zps40731722.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01185527_zps40731722.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01185922_zps7cf4bd02.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01185922_zps7cf4bd02.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190518_zpsa32db400.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190518_zpsa32db400.jpg.html)
New tool :)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190027_zps1c6d3c3e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190027_zps1c6d3c3e.jpg.html)
Ready to go
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190939_zpscf33ff37.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01190939_zpscf33ff37.jpg.html)

made in England :)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01191021_zpsa0d5fa2f.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-01191021_zpsa0d5fa2f.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02143504_zps4b256a9d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02143504_zps4b256a9d.jpg.html)
Genuine new bolts with threadlock
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02143739_zpsccb377d3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02143739_zpsccb377d3.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02145722_zps74156daa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-02145722_zps74156daa.jpg.html)

[ZS Phil]

New oil seals
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-03183513_zps9cc60506.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-03183513_zps9cc60506.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-03183945_zps2fb76786.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-03183945_zps2fb76786.jpg.html)

Short shifter:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-04204612_zpse3790489.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-04204612_zpse3790489.jpg.html)

New roll pin and polybushed
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-04205701_zpsad75600d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-07-04205701_zpsad75600d.jpg.html)

MTF94
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-08-08140951_zps84304e91.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-08-08140951_zps84304e91.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20clutch%20and%20gearbox/2013-08-08142210_zpsef1282e5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20clutch%20and%20gearbox/2013-08-08142210_zpsef1282e5.jpg.html)

[ZS Phil]

Now onto that all important turbo, there have been some big changes with this but still the same turbo GT1852V.

First of all I wittled down from two adaptor plates to one so it sits higher and is neater:
http://i276.photobucket.com/albums/kk11/zsphil/IMAG0092.jpg (http://s276.photobucket.com/user/zsphil/media/IMAG0092.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/IMAG0093.jpg (http://s276.photobucket.com/user/zsphil/media/IMAG0093.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/IMAG0104.jpg (http://s276.photobucket.com/user/zsphil/media/IMAG0104.jpg.html)

The next big change was to the manifold. I am running an external wastegate as well as the electronic vane control:
How the EGR port started:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22183433_zps7c4b12a6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22183433_zps7c4b12a6.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22183458_zps915fdb64.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22183458_zps915fdb64.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22191001_zps1b98a763.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22191001_zps1b98a763.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22200031_zps4087461b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22200031_zps4087461b.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22203937_zps111c5ea1.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22203937_zps111c5ea1.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-22205456_zps586521ba.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-22205456_zps586521ba.jpg.html)

I then used the second of the original adaptor plates to make a plate for the wastegate to sit on and the valve seat overlapped the manifold otherwise.
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-07133402_zps325023ab.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-07133402_zps325023ab.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-07141308_zpsc392e640.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-07141308_zpsc392e640.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-07141320_zps985c60c1.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-07141320_zps985c60c1.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-07142236_zps9f5c2259.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-07142236_zps9f5c2259.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-07142420_zps38df9694.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-07142420_zps38df9694.jpg.html)

Next, I wanted to clock the turbo so that the oil drain was completely vertical. Not that straight forward with a VNT as you have to rotate the whole internal mechanism the same amount as you rotate the external part. This meant re drilling and lots of measuring...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28190557_zpsc12d1f61.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28190557_zpsc12d1f61.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28190912_zpsdcc3c6e6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28190912_zpsdcc3c6e6.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28191911_zps0bc77430.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28191911_zps0bc77430.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28194736_zpsfecb5528.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28194736_zpsfecb5528.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28202724_zps1b9e0dba.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28202724_zps1b9e0dba.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28212941_zpsd61acd89.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28212941_zpsd61acd89.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28215935_zps9bb28796.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28215935_zps9bb28796.jpg.html)

Not so vertical
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28192937_zps8df2a9fb.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28192937_zps8df2a9fb.jpg.html)

After the above work :)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-28192951_zps342a3c58.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-28192951_zps342a3c58.jpg.html)

[ZS Phil]

I was now left with nowhere to put my EMP gauge tap so did this:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-30175228_zps419d21ed.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-30175228_zps419d21ed.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-30175212_zpsb414c7cd.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-30175212_zpsb414c7cd.jpg.html)

Custom washer
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-30180207_zps24f87279.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-30180207_zps24f87279.jpg.html)

In place
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-06-30183232_zpsa8246122.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-06-30183232_zpsa8246122.jpg.html)

The downpipe was then modified for the wastegate:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-26161316_zps14710caa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-26161316_zps14710caa.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-26161328_zpseb98c0c5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-26161328_zpseb98c0c5.jpg.html)

All together looking like a bit of a monster :)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170743_zpsae69e5a0.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170743_zpsae69e5a0.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170731_zps65e1a377.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170731_zps65e1a377.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170657_zpsba17248c.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170657_zpsba17248c.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170757_zpsf33fe721.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170757_zpsf33fe721.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170831_zps35a39651.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170831_zps35a39651.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170808_zps8de0b15f.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170808_zps8de0b15f.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20turbo/2013-07-25170921_zps6672f2df.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20turbo/2013-07-25170921_zps6672f2df.jpg.html)


So with all that boost I then decided I needed something more up to the job of cooling it...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-07-09150426_zpsd7d2eb3e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-07-09150426_zpsd7d2eb3e.jpg.html)

A teaser
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-07-09150541_zps2a1db570.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-07-09150541_zps2a1db570.jpg.html)

Making the brakets and fitting:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04110248_zps8f4c7bfa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04110248_zps8f4c7bfa.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04111531_zps5cfd8a13.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04111531_zps5cfd8a13.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04122343_zpsbeb5ac2a.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04122343_zpsbeb5ac2a.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04115101_zpsdf937490.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04115101_zpsdf937490.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04120815_zps170fb239.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04120815_zps170fb239.jpg.html)

The aircraft grade TV airial based top mounting
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04131326_zps45a12f58.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04131326_zps45a12f58.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04141803_zps384c97cb.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04141803_zps384c97cb.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04144041_zps767d49b4.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04144041_zps767d49b4.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04150549_zps57428251.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04150549_zps57428251.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04150502_zps51658eb3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04150502_zps51658eb3.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04150532_zps296ad81b.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04150532_zps296ad81b.jpg.html)

Bits to cut out to avaid removing the air con...
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04152450_zps943ec9e6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04152450_zps943ec9e6.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04152443_zpsd529bf93.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04152443_zpsd529bf93.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-04193621_zps2b589418.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-04193621_zps2b589418.jpg.html)

[ZS Phil]

Modification of the rad is required because normally the near side is supported by the original intercooler which is obviously no longer there.
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05181254_zpsbceb95ff.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05181254_zpsbceb95ff.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05182425_zps537522ce.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05182425_zps537522ce.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05182457_zps764ec1ce.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05182457_zps764ec1ce.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05182525_zps51c69c76.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05182525_zps51c69c76.jpg.html)

A surplus bracket, recycling at its best.
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05183314_zpse6be35f8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05183314_zpse6be35f8.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-05192612_zpsdeaa5395.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-05192612_zpsdeaa5395.jpg.html)
(It was since painted with basically every other braket in the engine bay)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/2013-08-06211020_zps02c6a326.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/2013-08-06211020_zps02c6a326.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/2013-08-07214609_zps5fef3791.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/2013-08-07214609_zps5fef3791.jpg.html)

Satainless nuts and bolts EVERYWHERE!
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-08154922_zpse597baf3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-08154922_zpse597baf3.jpg.html)

PIPES!
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12080942_zpsaaea6bc5.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12080942_zpsaaea6bc5.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12080956_zps0a753c54.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12080956_zps0a753c54.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12081050_zps539af553.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12081050_zps539af553.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12081115_zpsc2585205.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12081115_zpsc2585205.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12081133_zpse416b494.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12081133_zpse416b494.jpg.html)

Another nifty bracket
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12081424_zps3a584391.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12081424_zps3a584391.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12081443_zps114c5b80.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12081443_zps114c5b80.jpg.html)

Polished ECU
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12194640_zpsf2ac8d1a.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12194640_zpsf2ac8d1a.jpg.html)

Green cotton filter
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rebuild%20intercooler/2013-08-12194657_zpsbf1e58c8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rebuild%20intercooler/2013-08-12194657_zpsbf1e58c8.jpg.html)

Suspension and rust proofing, never got any pics after Id cleaned up the suspension stupidly, just image they look almost new.

The GAZ coilovers were another cheeky upgrade I bagged while the car was off the road.

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20suspension/2013-08-12213514_zps691e963e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20suspension/2013-08-12213514_zps691e963e.jpg.html)
Minted up rear ARB
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20suspension/2013-08-16153922_zps51a7e798.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20suspension/2013-08-16153922_zps51a7e798.jpg.html)
More stainless
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20suspension/2013-08-16154013_zpseea2eb98.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20suspension/2013-08-16154013_zpseea2eb98.jpg.html)


With the extra power, some extra brakes were needed. 620 TI calipers up front with 282mm discs, V6 rear brakes
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-06-27140919_zps87530383.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-06-27140919_zps87530383.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-06-27140934_zps8ece92d6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-06-27140934_zps8ece92d6.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-06-27140956_zps1a91e849.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-06-27140956_zps1a91e849.jpg.html)

Modifying the Ti carriers:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-10110108_zps506fc649.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-10110108_zps506fc649.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-10162257_zps51f1add4.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-10162257_zps51f1add4.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-10145833_zps13c00359.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-10145833_zps13c00359.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-22170458_zpsc2ff93ff.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-22170458_zpsc2ff93ff.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-22170512_zps1099c8c7.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-22170512_zps1099c8c7.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-22181152_zpsca3ee168.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-22181152_zpsca3ee168.jpg.html)

[ZS Phil]

Old vs new
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-22185051_zps9ec10389.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-22185051_zps9ec10389.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20brakes/2012-07-23125201_zpsd179951d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20brakes/2012-07-23125201_zpsd179951d.jpg.html)


Those pretty brakes needed some pretty wheels to sit behind, behold the pro race 1.2s
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20wheels/2013-02-07182652_zpsd964c7aa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20wheels/2013-02-07182652_zpsd964c7aa.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20wheels/2013-02-07183005_zps33cb8510.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20wheels/2013-02-07183005_zps33cb8510.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20wheels/2013-02-07182905_zps32088461.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20wheels/2013-02-07182905_zps32088461.jpg.html)

New Kumho tyres 40,205,17. They are the Ecsta sports, best tyres Ive ever had. Grip like nothing else!

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20wheels/2013-08-27180952_zps188bae69.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20wheels/2013-08-27180952_zps188bae69.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20wheels/2013-08-27180937_zpsacf9880c.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20wheels/2013-08-27180937_zpsacf9880c.jpg.html)

Back to those horrible bits of bodywork at the beginning, I finally found some skirts in the right shad of silver but the bumpers and front splitter are like hens teeth in this colour, never mind finding them in mint condition. I therefore settled on a genuine splitter in blue and had that along with the bumpers painted professionally:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/2013-08-07115948_zpsbe7ed604.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/2013-08-07115948_zpsbe7ed604.jpg.html)

Off they go in the other halfs 45 TD
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/2013-08-07124600_zps808a594e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/2013-08-07124600_zps808a594e.jpg.html)

New plates
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-08-21200828_zps71453470.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-08-21200828_zps71453470.jpg.html)

Powder coated mesh
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-08-13214111_zpsa189a026.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-08-13214111_zpsa189a026.jpg.html)

Old vs new again
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-08-21200949_zps1291b7bc.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-08-21200949_zps1291b7bc.jpg.html)

Bargain mats from rimmers and chrome kick plates
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuid%20new%20bits/2013-08-23131802_zpsae4b66a6.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuid%20new%20bits/2013-08-23131802_zpsae4b66a6.jpg.html)

[ZS Phil]

So, finally, after 6 months off the road, she returns...

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/2013-08-20161150_zpsd0517ec4.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/2013-08-20161150_zpsd0517ec4.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1325_zps753298bb.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1325_zps753298bb.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1329_zps7bbec760.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1329_zps7bbec760.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1333_zpse4d350eb.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1333_zpse4d350eb.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1335_zpscf4f0024.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1335_zpscf4f0024.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1337_zps6a44ae24.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1337_zps6a44ae24.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1338_zps7a7b8d16.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1338_zps7a7b8d16.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1342_zpse41e842f.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1342_zpse41e842f.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1344_zps70c43b3d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1344_zps70c43b3d.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1348_zps7498c2d8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1348_zps7498c2d8.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1351_zps95149a1d.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1351_zps95149a1d.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1353_zps8ae74684.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1353_zps8ae74684.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1354_zps5b9f49fa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1354_zps5b9f49fa.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1357_zps0f0646bd.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1357_zps0f0646bd.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1363_zps12b1c570.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1363_zps12b1c570.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1369_zps1545c0de.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1369_zps1545c0de.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1370_zpsa3047ec9.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1370_zpsa3047ec9.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20finished/IMG_1371_zps530011b2.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20finished/IMG_1371_zps530011b2.jpg.html)


And thats where Im up to, just need to get a remap sorted now on a rolling road and see what she can do.

I'm off to make a brew.

[carmadbaker]

Christ mate, impressed isn't the word! that looks brilliant and your attention to detail is phenomenal! Great thread too! Was actually gutted when it finished :(
Good luck with the rollers, what sort of numbers are you hoping for? I think i want your car :)

[Dan1971]

Awesome mate .... Great work.

[caled]

Awesome work

[Dr Doggystyle]

very nice work looks great
would love to have the intercooler like that at the same place behind the bumper

[peterzs]

Thanks for taking the time and effort in posting up, good pics, when I bet all you wanted to do, was get that bit finished and to start the next.

Great thread, and what engineering skills.

Awesome car, think I'm doing well fiddling about with my derv, but this has left me gobsmacked.

Will be interesting to see what torque and BHP you get from the remap.

Love it.

:thankyou: :clap::clap::clap::clap:

[ian zs180]

Great thread mate and your zed looks a different car from when you started that is a credit to you looks amazing now .

[petet16]

That was a really good read, some great pics as well.

[talkingcars]

Hi all, thought I'd share with you guys.

You may have seen my threads over on .org where there is a big diesel community but figured although its not a v6 or yellow some of you may still appreciate it.[/IMG][/URL]

Er yes - simply stunning attention to detail.

[ZSbhoy_1724]

she looks well mate great job done on it the v6s are great but you just cant beat an L-series diesel

[ZS Phil]

Thanks for all the kind comments :) appreciate it. Likewise though, if there is anything people dislike dont be afraid of letting me know, may well be constructive.


Was actually gutted when it finished :(
Good luck with the rollers, what sort of numbers are you hoping for? I think i want your car :)

Haha I can bore you all with the electronic controller for the VNT mechanism if you like...

With regard to figures Ill be pleased with anything over 160 bhp and 250 ft/lbs torque- that seems to be the max achieved with the standard turbo so anything above that is new territory.
Must admit though a 50mpg ZS 180 has a certain ring to it ;)

Im booked in with Dakta at Darkside developments first thing Monday morning so figures may be closer than anticipated. Hes crazy busy though so hope all goes to plan.
Darkside specialise inVAG stuff but Dakta (Kris) has played about the VNT stuff on L series cars himself and has a sound reputation on .org so Im fairly confident Ive got someone who has suitable experience with this type of thing.
The only other option was Reidy but given the distance its not an option, like I say, Kris seems a sound guy.

Just need to up the boost to 24psi in the mean time from the 20 Im running at the moment. Apparently 24psi is conservative for the 1852v but conservative sounds good to me as its my daily ride so needs to be reliable as well as fun

Haha, if you really want my car, come round with your turbo and Im sure a deal could be done ;) Only playing, mine isnt quite in that legue just yet and couldnt bear to watch her drive away after all the work Ive put in, sure youre the same.

[Maxfly]

Wow!! Excellent work, great pics showing the road to your zs's return.

[andys1981]

what an excellent thread,a lot of time/money/effort has went into bringing your car back,and better,well done,think youve done very well,car looks great.

[welshone]

Great thread. These kind of threads help motivate others do stuff to they're cars. Good work :thumbsup:

[peterzs]

scare me off!!!!

[p_b82]

Second read through still sdoesn't stop me from being impressed with the work :)

I think that while i know Kris and Reidy dont see eye to eye anymore, You do not have to worry about his work. If you have seen what he has done with the some of the VAG stuff his attention to detail is incredible too - You should get some nice figures out of it.... tho as we know Kris smoke levels may be the controlling factor to what they are precisely ;)

Can't wait until i get my turbo sorted once and for all - but it is still at the 'in the pipeline' phase - but getting ever closer :)

[welshone]

scare me off!!!!

You've already done quite a bit to yours Peter :) Unlike mine which i've hardly touched never mind driven since i've had it :laugh:

[talkingcars]

You've already done quite a bit to yours Peter :) Unlike mine which i've hardly touched never mind driven since i've had it :laugh:

Trust there'll be a thread?

[dida4g]

Awesome Sunday morning read.

[peterzs]

Tell you what Welshone, one of the downsides, with my one at least, is that you have to wash the back end down after a spirited drive!!!!

But its worth it!!

After all the work and upgrades, ZS Phil's will be awesome.

:clap::clap::clap:

[Ritchy]

Great thread, looks great

[Enright]

Superb attention to detail - a really enjoyable read. I notice you had a Mk2 grille though - did you decide against fitting it?

[ZS Phil]

Thanks again for all the comments, really does mean a lot :)

Had the car on the rollers on Monday,
Ill let the figures do the talking.
Standard: 101 PS / 177ft/lbs
Monday: 132 BHP / 230 ft/lbs
Now: 166 BHP / 300 ft lbs

That was 28psi boost but the exhaust manifold pressure was 26 psi so a ratio of less than 1:1 which is brilliant. As Im sure p_b82 will testify.

Exhaust manifold pressure on the standard turbo was 30 psi at just 19psi boost and that was before extra fuel was added.

The clutch held the torque no problems so a worth while upgrade.

Was very little smoke with the fuel pump maxed out on the SDI injectors so fuel is the limiting factor here.

Got some different injector nozzles on their way to experiment with so more to come :D

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Rolling%20Road/Dyno1_zpsd249bfce.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Rolling%20Road/Dyno1_zpsd249bfce.jpg.html)

[peterzs]

Good results, bet it goes.

:smile1::smile1::smile1:

[p_b82]

nice results - same as my car currently runs up top - but without an exploding HG. well done to you and getting the ardino setup correctly.

you trying the 300TDi nozzles then, or darkside got something magic up his sleeve for you?

[ZS Phil]

Im going to try a few things because Im really in the unknown now. On the list to try is:
Wingy injectors
200tdi nozzles on standard zs bodies
300tdi nozzles on standard zs bodies

Beyond that Im a bit stuck for ideas really. To be fair if non of the above work its not the end of the world, she pulls like a train now but doesnt smoke like one so I suppose I should be happy with what Ive achieved and stop there. As we all know, its never the way with cars...

Ive been meaning to ask by the way, what are your experiences with injectors over the years?
Ive only ever run my SDIs so far.

[p_b82]

Yeah, it is never easy and a lot are unknown.

I would be wary about long term issues unless the spray patterns are verified to be correct - just because they are unknown really. the angle might be right but they may not squirt it into the correct location on the bowl.

I have used wingy's that I felt were not running right as they smoked and smoked and smoked. Matt could not get the torque up on them.
I sold them to byronstigly on .org and in his SDI they were slower - I got my hands on a second set and sold them to him and they worked for him.

I then swapped out to the hybrid injector - been using that ever since and have little smoke on them as it stands.

I have never used standard SDI's, so i dont know, but I was told by Matt that he did not think the hybrid flowed quite as much as SDI's... .org didn't think that should be the case.

I know for a fact they are a lot less smokey based on a number of people popping them in after using SDI's.

[ZS Phil]

So did you never run with the second set which you sold to Byronstingly?

Ive won a complete set of 300tdi injectors on ebay which are on their way and Im bidding on a set of 200tdi injectors so plenty of experiments to come.

Ive no idea how to test or get the spray angles tested for similarity, you dont have any ideas do you?

[p_b82]

No never put a set i was comfortable with in, and didn't need them on the hybrid injectors (sdi nozzle on zs body) got me up to 170 and 270 and no smoke....

well as we know that is more than the turbo can take and the rest is history.

I would think you need to get them sent off to a specialist - though you *might* be able to set up your own test bed on a bench with a spare fuel pump - but no idea on how you go about working out what the patterns are and if they would be suitable I am afraid.

Kris may be able to help give you pointers on that one though.

[ZS Phil]

Time for an update,

So, since the rebuild she has been such a joy to drive and own, no other car has put a grin on my face in the same way this one does, especially since the remap.

The turbo is still working a treat with no seized vanes and the controller is still reliable and working well with the external wastegate.

Other than the routine maintenance, the only other mods have been carried out today and are possibly of interest to a few...

The picture below shows a few of my sets of injectors, in addition (not shown in the pic) are another set of standard 210 bar ZS injectors and the SDI injectors which were in the car when that picture was taken.

Top left, another set of standard ZS injectors
Top right 200tdi injectors
Bottom left, Dans clamps (before I finished them off)
Bottom middle, 300tdi injectors
Bottom right, 300tdi clamps (no use but they were sent with the injectors)
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0126_zpsa776f2d6.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0126_zpsa776f2d6.jpg.html)

So I first made a set of hybrids using the standard 210 bar bodies and the nozzles taken from the 300tdi injectors.
Looking at the holes on the end, I double checked the angle which the injector needed to be rotated, it correlated perfectly with the angle Dan's clams were set at:
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0131_zps8849978b.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0131_zps8849978b.jpg.html)

The difference in angulation required to place the spray holes correctly
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0132_zpscea3646b.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0132_zpscea3646b.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0133_zps1e730bb9.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0133_zps1e730bb9.jpg.html)

The finished 210 bar/ 300tdi hybrids:
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0135_zpsfae0e043.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0135_zpsfae0e043.jpg.html)

And the clamps:
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0137_zps24562a5d.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0137_zps24562a5d.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0136_zps92f1b23e.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0136_zps92f1b23e.jpg.html)

I fitted them this morning:
First impressions were not good, lots of white smoke on start up and it was slow to start too, even once warm but it did get quicker as they day went on. Idle wasnt great either, fairly lumpy.
That is where the bad news ended though, I did a 70 mile drive with them and they were so much fun, in-gear acceleration can only be described as savage, much quicker than the SDIs.
Despite my car being quicker than ever, they need more work before Im happy with them so as soon as I got home I was straight in the garage making the second set of hybrids:




So for these, I dug out a second set of standard 210 bar ZS injectors and mated them with the nozzles from the 200 tdi injectors:

Left, 200tdi injectors
Right, second set of standard ZS injectors
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0139_zpsba37252b.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0139_zpsba37252b.jpg.html)

Unlike with the 300tdis, you can see here the angle is the same between standard ZS nozzle and 200tdi nozzle:
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0140_zpse3c690bf.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0140_zpse3c690bf.jpg.html)

So there we have it, the completed 210 bar/ 200tdi hybrids on the right:
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0141_zpsf02eeafa.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0141_zpsf02eeafa.jpg.html)


First impressions of these are much better. It still pulls really hard (not quite as hard as the 300tdi hybrids lower down though) but it idles like standard and should hopefully fire up like standard too, Ill report back once Ive done a proper cold start. Being dark, I cant see exactly how much smoke they make but Im willing to bet there is a fair old cloud on hard acceleration.

So far though, the 200tdi hybrids are looking pretty good and the 300tdi hybrids have potential but I think require better atomization to improve the idle and starting, maybe increasing the break pressure above 210 bar would help? They are definitely amazing fun though just not for a daily driver in winter!

[peterzs]

Good read, good luck with it.

What does it sound like at tickover???

[p_b82]

as i said over on .org that is really good info.

I would be really interested to see the dyno plots of both sets just to look at the way the torque is generated.

Having been bitten by the wingy's once, I am a little suspicious of too much fuel being thrown at things with not suitable atomisation/control etc.

[ZS Phil]

So, another quick update for anyone interested.

I had a problem with the car slowly losing water which was gradually getting worse. I located the issue to either the seal between the water pump housing and block or the water pump itself. Both areas were wet so naturally I went all out and replaced all the seals. Taking the mounting bracket off was a bit of a pig but it has fixed the problem so well worth doing

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0161_zps9a4cbcd8.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0161_zps9a4cbcd8.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0159_zps050eb149.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0159_zps050eb149.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0160_zps7bacbd32.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0160_zps7bacbd32.jpg.html)

New pump, there are rubber seals below the silicone
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0162_zps41964ed1.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0162_zps41964ed1.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0158_zpscf132c2e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0158_zpscf132c2e.jpg.html)

I was then on a roll so decided to replace the crappy after market cam cover gasket for a genuine Land Rover one. At the same time I took the belts and pulleys off allowing me to remove the cam carrier and re seal that with the genuine Rover sealant just to be on the safe side.

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0165_zpse949426c.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0165_zpse949426c.jpg.html)

Cam removed
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0164_zpsd3069aaa.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0164_zpsd3069aaa.jpg.html)

Quick de-grease and going back together
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0166_zpsd981c6d3.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0166_zpsd981c6d3.jpg.html)

All back together and filled up with new OAT coolant, now completely oil leak and coolant leak free.
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0169_zps051a2f6e.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0169_zps051a2f6e.jpg.html)

Then we gave them both a quick wash:
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20Water%20Pump/IMAG0155_zps9b683414.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20Water%20Pump/IMAG0155_zps9b683414.jpg.html)

In other news I have sent a set of ZS injectors to United Diesel to be re-built with new Firad nozzles and both opening pressures increased. They have also been completely balanced and flow tested.

These results show the difference in flow between standard nozzles and the DSLA 145P 208 nozzles.

If anyone wants the exact specs of what has been done I'd be glad to help.

Cant wait to get these fitted on Sunday.

Also Ive given my turbo map another tweak on my other 200tdi hybrid injectors and she really is flying at the minute.

Just need to get my new turbo core fitted now and oil drain to sump, then maybe a hard cut limiter (just for giggles) and she will be virtually finished (3 years on)

http://i276.photobucket.com/albums/kk11/zsphil/Injectors/PhilBowden_zpsb43c0eef.jpeg (http://s276.photobucket.com/user/zsphil/media/Injectors/PhilBowden_zpsb43c0eef.jpeg.html)

[fastmike]

Awesome project and workmanship

[peterzs]

Love the detail, make it sound so easy, when its so hard and time consuming.

:yay::yay::yay::yay:

[talkingcars]

and she will be virtually finished (3 years on)


Modified cars are never finished..............................:laugh:

[ZS Phil]

As always, thanks for the comments. Too true about modified cars never being finished but we'll see.

[p_b82]

wow - should see some much better figures with that extra flow!

watching with bated breath as ever :)

[dida4g]

I had the same issue with the coolant, big thanks for the pics.

[ZS Phil]

I managed to get my new injectors fitted.

Link to the company who did the work: https://www.uniteddiesel.co.uk/

Specs of the injectors:
Firad 145P 208 nozzles (aka 200 tdi nozzles)
First stage opening pressure set to 220 bar
Flow tested and balanced (see print out in previous post- very well balanced)
All cleaned up and amazing presentation, they look like new:

I posted them to united diesel after helpful emails being exchanged, we agreed on the specs of the injectors and they were posted.
He got to work on the injectors straight away and had them finished on Thursday last week. I got a phone call at 4:30 saying they were done and they arrived the next day, amazing service.

This is how they were returned:

http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0171_zps28679c08.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0171_zps28679c08.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0172_zps759366b5.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0172_zps759366b5.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0174_zpse3d3fb99.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0174_zpse3d3fb99.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0175_zps8c83253e.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0175_zps8c83253e.jpg.html)

Comparison before and after:

http://i276.photobucket.com/albums/kk11/zsphil/Injectors/IMAG0179_zpsfba6f1db.jpg (http://s276.photobucket.com/user/zsphil/media/Injectors/IMAG0179_zpsfba6f1db.jpg.html)

The engine starts just like standard, I cant notice any increased diesel knock and they are just so smooth.

Anybody wanting an awesome injector upgrade, you have all the info here you need, so refreshing to got such good service from a company.

United Diesel, recommended!

Anyway, gave her a clean an got all patriotic:

Before:

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/IMAG0181_zps527e4aef.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/IMAG0181_zps527e4aef.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/IMAG0192_zps375f7e42.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/IMAG0192_zps375f7e42.jpg.html)

After:

http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/IMAG0196_zps8f469032.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/IMAG0196_zps8f469032.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/ZS%20rebuild%20misc/IMAG0195_zps32b76171.jpg (http://s276.photobucket.com/user/zsphil/media/ZS%20rebuild%20misc/IMAG0195_zps32b76171.jpg.html)

[ZS Phil]

Also,
I've had my up-rated core to fit since November but not really had chance to fit it. So I took advantage of the lovely weather we've been having over the last couple of weeks and cracked on with it.
Its completely brand new with staggered oil seals (for running higher boost and low back pressure exhaust) and professionally balanced.

Cant say the box wasn't well boxed in the box for the box... :D

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0214_zps04b9fbd9.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0214_zps04b9fbd9.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0216_zpse05629ca.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0216_zpse05629ca.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0215_zpsddfc0e3d.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0215_zpsddfc0e3d.jpg.html)



Gave the VNT mechanism a good strip down and clean while I was there.

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0219_zpsaa7e2518.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0219_zpsaa7e2518.jpg.html)

After:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0221_zpsaddac714.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0221_zpsaddac714.jpg.html)


All re-assembled and setting the actuator up with a vacuum pump:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0228_zps65f86fd5.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0228_zps65f86fd5.jpg.html)


While I was at it I wanted to re-do the oil drain. It worked the way it was but was far from ideal so it was sump off time!

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0244_zpsf40bfdb6.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0244_zpsf40bfdb6.jpg.html)

Modified a standard ZS oil drain to bolt up to the sump and made a custom gasket:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0240_zps5d4de4e0.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0240_zps5d4de4e0.jpg.html)

Found some pipe perfect for the job:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0243_zps72fcd7c0.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0243_zps72fcd7c0.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0248_zpsed003aae.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0248_zpsed003aae.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0245_zpse7cc7953.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0245_zpse7cc7953.jpg.html)


I then needed something to bolt to the turbo and discovered this accidentally on ebay. Its the drain from an earlier 420d which has a much longer corrugated section, perfect for the job!

It came like this:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0242_zps09f0e871.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0242_zps09f0e871.jpg.html)

And I modified it to this:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0256_zpsca05e036.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0256_zpsca05e036.jpg.html)

Completed it looks like this:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0270_zps11d020bf.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0270_zps11d020bf.jpg.html)

New genuine sump gasket and fresh oil and filter at the same time:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0272_zps20baaa36.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0272_zps20baaa36.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0253_zpsce30da6a.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0253_zpsce30da6a.jpg.html)


To blank the original hole in the block, the local hydraulic shop sorted me out with this:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0251_zps2aa37f94.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0251_zps2aa37f94.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0252_zps68eafcc3.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0252_zps68eafcc3.jpg.html)

I also got around to fitting my new splitter, a sneak peak here:

http://i276.photobucket.com/albums/kk11/zsphil/New%20core%20and%20drain/IMAG0275_zps4c6e3985.jpg (http://s276.photobucket.com/user/zsphil/media/New%20core%20and%20drain/IMAG0275_zps4c6e3985.jpg.html)

Ill take some pics of it from the visible side when I've given the car a polish.

[peterzs]

Can they upgrade the o/e injectors???

Or do they want the SDi's???

Love the mods.

[ZS Phil]

Can they upgrade the o/e injectors???

Or do they want the SDi's???

Love the mods.

Thanks Peter,

They can upgrade either stock or SDI injectors. They are really just the same apart from the nozzles and opening pressures and since both of these are modified it doesn't matter which they start with I wouldn't have thought.

They set the first stage to 220bar and the second stage was set by looking at flow rates. I sent the stock injectors.

That said, for anybody with SDis, a remap and standard turbo these are pointless...
However for people requiring more fuel after a turbo upgrade OR if they have a standard car and fit these with the standard map I think it would have a similar effect to fitting SDIs and a remap. These with a remap and standard turbo however is asking for a smoke screen!

[peterzs]

Cheers Phil, that was what I was wondering, have a quick blast of smoke, but its only when first booted and it does go off.

Wont bother with the upgrades as I'm happy with my ones performance!!! :devil:

:beer2::beer2::beer2:

[ZS Phil]

Fair enough :)

I suppose they could also re-build your SDI injectors to standard spec and re-balance them should they ever get tired. Apparently the nozzles wear away and the spray pattern deminishes over time, 100K miles is a figure which floats around but not sure how significant it all is.

As long as your happy is all that matters, they certainly do shift with the right mods even with the standard turbo :). In all honesty I do this because mechanistry is a hobby and I get as much enjoyment from tuning the car as I do from taking it for a blast. Performance on yours will be way more than a match for most modern traffic.

[p_b82]

I reckon that the 200 nozzles will be too much for a OE turbo on anything but a 101 map, and still think that smoke would be pretty epic.

I've seen some of the more aggressive remaps with SDI's and the smoke levels is way higher than I would put up with - and why I downgraded from my wingy's (and also cos they were faulty).

I am still curious what nozzles were used on them, so maybe i should send that set off when i get round to the last parts of the project!

[ZS Phil]

Another update...

Was back to see Kris at Darkside a few weeks ago to play around with the map since the new core and injectors had been fitted and I had played around with the map of the turbo.

We had the rollers for half the day and did loads of pulls, cutting a long story short, we decided to leave fueling as it was but changed the opening pressure on the wastegate as well as played around with the controller map so she now boosts at 29psi.

The amazing thing is EMP peaks at 23 psi, something you will simply not achieve with a non-VNT turbo with any kind of quick spool. Because of the external wastegate on my VNT set up there is no spike so literally have the best of both worlds.


I should say that the 197.7 result was with the rollers set with slightly higher resistance which helped the boost spool.
The 184 result was consistent with the dyno on shootout mode for FWD forced indiction cars.
The reason i am posting both graphs is because on the FWD forced induction mode (184bhp) the boost was dropping off to about 25psi. This does not happen on the road, on the road it sits at 29psi to the redline as it did with the rollers set to higher resistance when it pulled 197 bhp. Im not saying one is right and one is wrong, just trying to give the full picture.

Either way, safe to say its got well over 300 ft/lbs torque and considerably more power than a ZS180, needless to say it is quick.

It was always my aim to have a 50+ mpg RELIABLE ZS with more power and almost double the torque of a standard 180. I think it has now been met.

http://i276.photobucket.com/albums/kk11/zsphil/Remap%202/184bhp_zps3127bd32.jpg (http://s276.photobucket.com/user/zsphil/media/Remap%202/184bhp_zps3127bd32.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Remap%202/197bhp_zps1f9ba5e3.jpg (http://s276.photobucket.com/user/zsphil/media/Remap%202/197bhp_zps1f9ba5e3.jpg.html)

[peterzs]

Good results.

:wave::wave::wave:

[Maxfly]

Very very impressive, a great result there :)

[adam]

That's a cracking amount of power right there.

[Lukeus101]

That is rather impressive. Well done mate!

[ZS Phil]

Cheers for the replies guys, pretty chuffed!

[ZS Phil]

Another little update since I've spend the day tidying.

Been meaning to get this wheel on since December!

How my steering wheel looked this morning:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0001_zps9835b37a.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0001_zps9835b37a.jpg.html)

New bits:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0003_zpsd60d9af6.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0003_zpsd60d9af6.jpg.html)

Close ups of an adapter which is required to self cancel the indicators:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0009_zpsb340b65d.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0009_zpsb340b65d.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0011_zps37c2985d.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0011_zps37c2985d.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0013_zpsb279d09c.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0013_zpsb279d09c.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0014_zps7a0d0d79.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0014_zps7a0d0d79.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0016_zps13ac0898.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0016_zps13ac0898.jpg.html)




ZS coupler:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0020_zps2d1f0f5e.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0020_zps2d1f0f5e.jpg.html)


Replaced with a TF one so it plugs straight into the TF airbag:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0023_zpsa638de9b.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0023_zpsa638de9b.jpg.html)



The finished product, such a good mod:

http://i276.photobucket.com/albums/kk11/zsphil/TF%20Wheel/DSC_0025_zpsab913d25.jpg (http://s276.photobucket.com/user/zsphil/media/TF%20Wheel/DSC_0025_zpsab913d25.jpg.html)

[petet16]

Looks great :thumbsup:

[Smokey]

This car must be priceless to you. A testament to the amount of time and effort put in!

[talkingcars]

Looks good - which airbag did you use?

When I got FE54 it had a TF wheel but the badge was black. I swapped the wheel on to the ZR and fitted my R45 wheel into the ZS, the smaller wheel suits the ZR better IMHO and doesn't need the adaptor.

[p_b82]

Congrats Phil - that is a cracking result there.

Even though there is so much more torque later in the rev range, you are still sing more than a standard car's peak at 1800rpm.

Really glad that the end result is what you wanted, and I am wondering whether the additional external wastegate is not the way to go as well on a future build of my own.

really well done there - am really pleased for you :)

[ZS Phil]

Sorry for lack of reply, only just checked the thread! As always, thanks for the comments.

Talkingcars, I used a TF airbag which plugs straight into the TF rotary coupler. I think there are different designs used for the badge in the F/TF, I specifically wanted the "coffee and cream" coloured one so waited until one came up.

p_b82, yeh, Im pretty pleased with the results, I think I've gone as far as I can with power whilst keeping a degree of reliability.
I'm definitely glad I fitted the WG for what it cost. It just gives so many options, you could even just set the vanes on any old VNT to a set position and then use it as a bigger externally gated turbo if you didn't want to bother with vane control.

Are you any closer to deciding on a turbo/ spec?

[p_b82]

Yes - but for now it is going to be a surprise until it is all sorted out, few things still need sorting out first.

Hopefully I will have a decent update in the not too distant future though - and that is all relative with this project of mine lmao :)

[tallgeese]

Fantastic work! The car is a testament to your mad skills ;)

[ZS Phil]

oooh I like surprises...

For those who can't be bothered with the VNT route (fair enough, its no walk in the park), it looks like Dark Ice Designs are making some progress with a bolt on kit which they are claiming should be good for 185bhp.
Personally however I think those figures are a bit optomistic for a wastegated GT17.

[p_b82]

Yeah - many people do, I would like to get it all sorted then share what details I can afterwards.

working out timings and costs really as the final hurdle - but as ever proving to be a little bit of a challenge due to the not off the shelf situation. but I'll work it all out in time I am sure :)

You might get 180+ with 200 nozzles, but I suspect emp will be high again with that. not going to be an option on SDI's only I don't believe.

[ZS Phil]

Its been a while so thought I'd give a quick update.
Nothing new mechanically, just lots of TLC.

Last shot of her with the winter wheels (if anyone wants to buy them, make me an offer):

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0073_zpse52b23cc.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0073_zpse52b23cc.jpg.html)


The TLC started with the summer wheels, gave them all a complete waxing which took hours and dressed the tires with gel. I also re-painted all the calipers in the same xpower green color to brighten them up:

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0077_zps5e10656a.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0077_zps5e10656a.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0082_zps9469d61b.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0082_zps9469d61b.jpg.html)


Next was the roof, see if you can guess whats going to happen :D:

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0091_zpsb9a63edf.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0091_zpsb9a63edf.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0093_zps10d7bc29.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0093_zps10d7bc29.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0094_zps242f3143.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0094_zps242f3143.jpg.html)

So these pics show the roof design half finished (more to come up there), they also show the splitter which I haven't posted before and the shiny new calipers:

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0096_zpsaaf44621.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0096_zpsaaf44621.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0100_zps249b567b.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0100_zps249b567b.jpg.html)



These caps are now on the car to complement the roof, I'll get more pics of the whole car when the design is finished:

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0104_zps4cb51f80.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0104_zps4cb51f80.jpg.html)

[adam]

Ooh, St George Cross or Union Flag?

[ZS Phil]

Ooh, St George Cross or Union Flag?

Good guess but not right... haha with the "made in the UK" sticker and "GB" badge on the back people would start to think I was a member of the BNP or something!

A clue is some MINIs have it however I've never seen one on the road, should be a bit different I hope :)

[adam]

Looking forward to seeing what it'll be!

[petet16]

Black and White chequered ?

[Steven11]

Confederate flag, general lee style

[ZS Phil]

All good guesses :)

However...

http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0106_zpsbd39f1e7.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0106_zpsbd39f1e7.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0108_zpsc5337dd0.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0108_zpsc5337dd0.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Summer%20wheels%20White%20roof/DSC_0107_zpscf9b6762.jpg (http://s276.photobucket.com/user/zsphil/media/Summer%20wheels%20White%20roof/DSC_0107_zpscf9b6762.jpg.html)

[adam]

Awesome! Motorhead inspired at all?

[ZS Phil]

haha slightly yeh plus the fact it's the highest card and also found out they tried to use it as psychological warfare in Vietnam. Amazing what Wikipedia can tell you :P

[ZS Phil]

Update time...

It's been a while but things have been changing in the background.

Having been running the custom injectors with the VNT for a good few months and a few thousand miles of daily driving the VNT mech had finally begun to slow down (hardly surprising with the amount of soot the injectors throw out).

It needs to be a reliable daily so with that in mind I decided to de-tune slightly by putting the standard turbo back on along with SDIs.

That lasted for 2 weeks...

Having gotten used to the power and torque of the VNT, the standard turbo wasn't cutting the mustard higher up the rev range so it had to go. The way I saw things were I could either re-fit the VNT and run it with SDIs so as not to clog it up every few thousand miles OR I could try something completely different, not yet tried on an L series as far as I know.

So, this is the end of the VNT chapter for now. It is all cleaned out and waiting on a shelf in the garage for some more action in the future maybe.

So, as always, lots of pictures and info so if anybody else wants a bigger turbo on their car too there are literally no excuses not to do it!

First of all, here is 1x VNT turbo kit with super clean silky smooth vanes safely in storage should it ever be called up for duty again in the future:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0147_zpsdbe2d71e.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0147_zpsdbe2d71e.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0141_zps12be32ea.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0141_zps12be32ea.jpg.html)


Out with the old and in with the new. The postman came with some presents:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0151_zps51f34b2a.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0151_zps51f34b2a.jpg.html)


But what's inside?

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0157_zpsf0ff78fd.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0157_zpsf0ff78fd.jpg.html)

As you can see, lots of turbo goodness including a blown GT2056s as used on Renault Trafic vans and Vivaro vans with the 2.5 dci engine between 2003 and 2006.

Part no. 714652

Other useful info:
Compressor inducer: 41.5mm
Compressor exducer: 56mm
A/R: 0.53
Trim: 55

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0158_zps193c6e3d.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0158_zps193c6e3d.jpg.html)



According to the seller there was just an oil seal gone but rather than rely on used parts I decided to replace the whole CHRA (cartridge) for a brand new uprated one from NKK turbos. This has staggered seals, uprated bearings and is completely balanced with print out.

Other than that, there are just loads of gaskets, some stainless exhaust sections and some steel plate for me to get creative with.

Some pics of the turbo, ties in with the blown oil seal story, oil everywhere!

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0159_zps70622b72.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0159_zps70622b72.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0161_zps0512813e.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0161_zps0512813e.jpg.html)

After a thorough clean/ de-grease:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0165_zps393d82f6.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0165_zps393d82f6.jpg.html)


A flange for the turbo end of the downpipe:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0168_zps13771cb7.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0168_zps13771cb7.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0170_zps8729e883.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0170_zps8729e883.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0180_zpsab1964d9.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0180_zpsab1964d9.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0176_zps7494474d.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0176_zps7494474d.jpg.html)


Recycling some old exhaust, I made a little partition to isolate the wastegate from the turbine outlet. I also made the flange look a bit prettier.

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0182_zpsd73cf98b.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0182_zpsd73cf98b.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0184_zps865503ea.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0184_zps865503ea.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0185_zps4ee87757.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0185_zps4ee87757.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0202_zps88450356.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0202_zps88450356.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0205_zpse343b382.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0205_zpse343b382.jpg.html)



Continuing the theme of recycling, I needed a flange for the other end of the new downpipe:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0138_zps3049d533.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0138_zps3049d533.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0145_zpsf165a512.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0145_zpsf165a512.jpg.html)



Before I could lock the wastegate shut properly, I needed to clock the turbo which is where the VNT came in very useful. Both turbos have the same manifold flange (so I didn't have to make another adapter plate) and also the compressor housings look to be exactly the same casting surprisingly. They have the retaining bolts in slightly different places and they are obviously machined to take the 52mm and 56mm compressor wheels accordingly.

One thing that did cross my mind was how easy it would be to make a VNT GT1856V using the compressor side from the GT2056s. Maybe something for the future?

Anyway, back to this... a clocked turbo and a few pics comparing the 1852V and the 2056S:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0197_zps7e707431.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0197_zps7e707431.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0198_zps4be86ad2.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0198_zps4be86ad2.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0199_zpsa15d0ff7.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0199_zpsa15d0ff7.jpg.html)


So now I could start my next piece of metal work... a means of keeping the internal wastegate shut:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0216_zps75a8ae96.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0216_zps75a8ae96.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0218_zpsee663dc3.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0218_zpsee663dc3.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0225_zps2457c2ec.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0225_zps2457c2ec.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0220_zpsed2dd204.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0220_zpsed2dd204.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0221_zps2874f284.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0221_zps2874f284.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0228_zpscec80d84.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0228_zpscec80d84.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0233_zps88bf8cd2.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0233_zps88bf8cd2.jpg.html)


All bolted together:

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0236_zpsba887cef.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0236_zpsba887cef.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0240_zps1ba34a7d.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0240_zps1ba34a7d.jpg.html)



And naturally it got the oil and filter dropped and new stuff put in.

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0242_zps67843430.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0242_zps67843430.jpg.html)


It is now all fitted and ready to go, I just need to get the downpipe parts welded together and a screamer pipe for the wastegate made. If its too loud I'll just plumb it back into the exhaust as with the set up with the VNT.

So I've got what could potentially be the next best thing in L series tuning or the next lemon. Really wish I could say which of the two it is but no downpipe means no drive yet.

Needless to say I'm excited to see how it is... watch this space.

[Lukeus101]

Wow, what an update mate! Some bloody hard work gone into it and will look forward to seeing how it performs ;)

[talkingcars]

Impressive work, is it kitchen table tuning or do you have access to a workshop?

[ZS Phil]

Wow, what an update mate! Some bloody hard work gone into it and will look forward to seeing how it performs ;)

Cheers mate, cant wait to drive it. So annoying having it sat there ready to go with just an exhaust section missing.

Impressive work, is it kitchen table tuning or do you have access to a workshop?

I suppose its a bit of both. I don't have access to a proper workshop, I just use my garage (as in single car garage at the side of the house, not a car repair garage) which is semi kitted out as a workshop. I've got a pillar drill, grinding wheel, metal work vice etc all bolted to a bench along with a good stash of hand tools so I can do most things by hand as one offs. Obviously those flanges took all day to make with just those tools so I wont be setting up a production line any time soon!

[peterzs]

Well done, love all the attention to detail.

Awesome car and looks so O/E, cant wait to see it again.

:yes::yes::yes:

[p_b82]

Nice one Phil - it is a shame to see that the 200TDI's clogged the VNT mech so fast though....

I think it is going to be interesting if we can find a sweet spot , but it seems that mapping will probably have to be done on a dyno, and a 'loooong' session too to get it right.

I really hope the lag is not too bad for you, as I think you will miss the low down response the VNT gave you - as going back to an OE unit, I understand they are fairly similar in terms of response characteristics.

I know the stage 2 is around 2000 before anything meaningful happens, and 2225 before full boost can be achieved.

I have to admit it is my biggest fear with the GTB purchase, the soot levels..... first stage is cleaning running on SDI hybrids though to get it bedded in and work on the controller tweaking!

[ZS Phil]

Well done, love all the attention to detail.

Awesome car and looks so O/E, cant wait to see it again.

:yes::yes::yes:

Thanks Peter :)

Hopefully it will all pay off. No doubt I will show my face at a few more events, had such a good time at the saloon day.

Nice one Phil - it is a shame to see that the 200TDI's clogged the VNT mech so fast though....

I think it is going to be interesting if we can find a sweet spot , but it seems that mapping will probably have to be done on a dyno, and a 'loooong' session too to get it right.

I really hope the lag is not too bad for you, as I think you will miss the low down response the VNT gave you - as going back to an OE unit, I understand they are fairly similar in terms of response characteristics.

I know the stage 2 is around 2000 before anything meaningful happens, and 2225 before full boost can be achieved.

I have to admit it is my biggest fear with the GTB purchase, the soot levels..... first stage is cleaning running on SDI hybrids though to get it bedded in and work on the controller tweaking!

The VNT sooted up with the hybrid injectors and the fuel pump virtually maxed out. Needless to say it was very smokey so not really surprising, it was a question of when not if. We did try reducing smoke with the hybrids by reducing the injection quantity but with the controller settings left as they were it wasn't boosting and obviously not making power. Changing the map and the controller map would have overcome this but there are so many variables and perameters in the VNT controller that it would have taken hours and hours so decided to leave things as they were and came away with some decent power runs and a hard cut limiter for good measure.

With SDIs back in now I'll see how the new turbo burns the fuel and then consider putting the 200's back in but if that happens I'll have to pay Kris a visit to reduce fueling again.

Regarding lag, I hope it isn't too bad too but from what I've seen on youtube and what I've read I believe I should be able to get 24-25psi by 2.5k rpm. If that is the case then it is no worse than my VNT. Time will tell I suppose because I'm not taking the 306 forum as gospel, just keeping an open mind until I know the facts.

Your GTB has a different vane design to my VNT so hopefully that should help with clogging. Also, you see the amount of smoke that comes out the back of tuned VAGs with the GTBs and they don't seem to have many problems. I'm sure you'll be fine.

I've said to Kris that when his controller is sorted I'll have one, VNT isn't off the cards for me completely, I just need a reliable daily driver for the next year hence keeping it old school and simple for now.

[p_b82]

Well I suppose that actually knowing what you had pushed through it, it was soot that was your issue not EMP or EGT is a promising sign for 200+ ponies and reliability... that was something that was still an unknown for most of us!

Part the reason that I wanted Kris's controller was so that the map and the vnt control can work in tandem, as it is not always about generating boost, but more about getting decent flow.... if you dont *need* 20+PSI to get a wave or torque then dont have it there ready and waiting.....

obviously WOT throttle requests change all that, but I haven't used WOT for so long I have got used to driving with the torque and can keep up quite happily with most things at road speeds.

I've not spent much time on the 306 one tbh, but spent a fair amount of research on the VAG one clubtdi i think it is, and that was why I went for the (pricey) GTB in the end.

I am sure we are not going to get the same level of power that they get out, as we have a lower rev limit from the factory (4200) even if mine will go up to 5400. but the exhaust manifold will be interesting to see if it makes any difference. we know from past experience from Donny, that the inlet one is *good* so this really is going to be my last power mods...

for me low smoke is important, James Bond smoke screens out the back is not what I am after, been there done that and it is fun, but dangerous ultimately...

i'd like to have a dual map option, one for track/pod use and one for everyday, but I might get round that with my right foot again lol.

Either way, fingers crossed that the new turbo does the job!

I still fear it will be the low down reponse that might prove a bit of a killer, as we we know they can bog down a bit with poor maf on the little GT15's.....

[ZS Phil]

Well I suppose that actually knowing what you had pushed through it, it was soot that was your issue not EMP or EGT is a promising sign for 200+ ponies and reliability... that was something that was still an unknown for most of us!

Part the reason that I wanted Kris's controller was so that the map and the vnt control can work in tandem, as it is not always about generating boost, but more about getting decent flow.... if you dont *need* 20+PSI to get a wave or torque then dont have it there ready and waiting.....

obviously WOT throttle requests change all that, but I haven't used WOT for so long I have got used to driving with the torque and can keep up quite happily with most things at road speeds.

I've not spent much time on the 306 one tbh, but spent a fair amount of research on the VAG one clubtdi i think it is, and that was why I went for the (pricey) GTB in the end.

I am sure we are not going to get the same level of power that they get out, as we have a lower rev limit from the factory (4200) even if mine will go up to 5400. but the exhaust manifold will be interesting to see if it makes any difference. we know from past experience from Donny, that the inlet one is *good* so this really is going to be my last power mods...

for me low smoke is important, James Bond smoke screens out the back is not what I am after, been there done that and it is fun, but dangerous ultimately...

i'd like to have a dual map option, one for track/pod use and one for everyday, but I might get round that with my right foot again lol.

Either way, fingers crossed that the new turbo does the job!

I still fear it will be the low down reponse that might prove a bit of a killer, as we we know they can bog down a bit with poor maf on the little GT15's.....

Your plans all sound good and I'm glad somebody else is sticking their neck out with a new turbo choice. Look forward to seeing the results... make sure you take lots of pics and keep us updated.
Hows the controller coming on by the way? We any closer to seeing the manifold?

[ZS Phil]

Pretty self explanatory really, just to show the downpipe and screamer pipe. One of them shows how the wastegate is plumbed in with the controller too if anybody was wondering.

A couple of poor quality vids of the screamer pipe. Still a bit undecided but I've got a baffle insert on the way to see if that makes it a bit quieter.

Windows up: http://www.youtube.com/watch?v=JBfhcrrUnGQ

Windows down through a short tunnel at the start: http://www.youtube.com/watch?v=2IugHKBeQLw

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0258_zpsbf4ecef0.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0258_zpsbf4ecef0.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0259_zpsdc81b8c8.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0259_zpsdc81b8c8.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0260_zpsbcbb0708.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0260_zpsbcbb0708.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0261_zpsbbe41701.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0261_zpsbbe41701.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0270_zps8aad8c97.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0270_zps8aad8c97.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0274_zps13f367c2.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0274_zps13f367c2.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0276_zps389c3d48.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0276_zps389c3d48.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0280_zps0b60dec6.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0280_zps0b60dec6.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/GT2056s/DSC_0277_zps1bb8e931.jpg (http://s276.photobucket.com/user/zsphil/media/GT2056s/DSC_0277_zps1bb8e931.jpg.html)

[talkingcars]

One of the reasons I want to learn to weld properly, wanna make my own exhaust for the maestro.

[ZS Phil]

Took a few pics today so here is as good a place to put them as any.

Some ducks stopped me in my tracks for a few minutes this morning on one of my favorite local roads and thought it made a nice picture:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0298_zps548730e8.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0298_zps548730e8.jpg.html)

Then I knew the MOT was due so popped into the garage on my way home. It passed first time with not a single advisory which I was chuffed about:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0329_zps0abe8b87.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0329_zps0abe8b87.jpg.html)

Since it was a nice day I decided to try out the baffle I got for the screamer pipe. Nice tight fit into the pipe, it was made for the job:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0300_zpsdcdf335f.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0300_zpsdcdf335f.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0303_zpsb55534b2.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0303_zpsb55534b2.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0305_zps9548da6d.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0305_zps9548da6d.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0306_zps6769d433.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0306_zps6769d433.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0308_zps1b8cbd4a.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0308_zps1b8cbd4a.jpg.html)

Then I went from this:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0313_zps6ab26d7f.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0313_zps6ab26d7f.jpg.html)

Got these:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0315_zpsf45834d9.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0315_zpsf45834d9.jpg.html)

Took a knife to my seats and finished up with this:

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0323_zpsa52c3b02.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0323_zpsa52c3b02.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Rear%20headrests%20and%20baffle/DSC_0325_zps1bfd7d3e.jpg (http://s276.photobucket.com/user/zsphil/media/Rear%20headrests%20and%20baffle/DSC_0325_zps1bfd7d3e.jpg.html)

[Lukeus101]

Awesome work Phil :) need vids ;)

[ZS Phil]

Funny you should say that, I've just finished uploading this:
It's rubbish...

Anybody any ideas on how to record good quality exhaust sound. What equipment to use and where to put it?

https://www.youtube.com/watch?v=RnFV-P27F30&feature=youtu.be

[peterzs]

Have to stop feeding the ducks!!

Brave taking a knife to the seats, but good result.

:laugh::laugh::laugh:

[ZS Phil]

Haha the duck are lucky I stopped in time, I thought they were leaves on the road from a distance.
Thanks Pete, I'm really pleased with them, make the rear look "finished" if you know what I mean.

[peterzs]

Yep, look good.

:thumbsup::thumbsup::thumbsup:

[adam]

Looks fantastic!

[p_b82]

looking good there Phil, the hard cut makes some quite amusing smoke 'bubbles' lol

[ZS Phil]

The track car has been stealing my attention a little bit recently but the TD is still going strong. Been nothing but a reliable mile muncher over winter so treated it to some TLC over the last few weeks.

First things first, now its summer virtually and I can wash it more regularly the bigger injectors are back in... for the first time on the GT2056 turbo.

The verdict... well at 25psi it shifts however the smoke cloud is just plain embarrassing if its anything other than a dark B road so I need to tweak the map for less fuel higher up and I need to up the boost a bit, should be good for up to 29 psi according to the compressor map however how far I take it depends on the exhaust manifold pressure.

Once I'm happy with it, Ill get it back on the rollers and hope I get an operator who doesn't mind a workshop full of volcanic ash (unless I re-route the screamer pipe back into the downpipe before then).

Anyway, enough boring diesel talk, some pics:

Hybrid injectors going back in

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0928_zpsfoy6q8hb.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0928_zpsfoy6q8hb.jpg.html)

The Team Dynamics wheels which are being donated to the track car and the state the calipers had got themselves into over winter:

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0935_zps8hmmfmfr.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0935_zps8hmmfmfr.jpg.html)

About 14 horsepower worth of green paint later:

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0934_zpsz7fmwzc1.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0934_zpsz7fmwzc1.jpg.html)


Next was the wheels, decided to get the straights which came on the track car done in the closest colour I could find to the Pro Race.

One-off center badges by "locking vinyl", they look awesome!

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0948_zps1jklp58z.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0948_zps1jklp58z.jpg.html)

New nuts:
http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0937_zpsafngxtc8.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0937_zpsafngxtc8.jpg.html)

Much better :)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0956_zpsrnxwcxk5.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0956_zpsrnxwcxk5.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0953_zpsl3jnlfxk.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0953_zpsl3jnlfxk.jpg.html)

All ready for POL:

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0957_zpsr4n2fjli.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0957_zpsr4n2fjli.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0961_zpstfxlioko.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0961_zpstfxlioko.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0962_zpst0ewwyd9.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0962_zpst0ewwyd9.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0968_zps69hmljfx.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0968_zps69hmljfx.jpg.html)


The big day...

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0972_zpsyk0zjb0j.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0972_zpsyk0zjb0j.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0994_zpsxkgamjvn.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0994_zpsxkgamjvn.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0995_zpsdoeljnjn.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0995_zpsdoeljnjn.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_0996_zpsurl4royo.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_0996_zpsurl4royo.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_1000_zpsyxaoqmfj.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_1000_zpsyxaoqmfj.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_1011_zpsvbtwxlre.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_1011_zpsvbtwxlre.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_1013_zpsvvirmhdi.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_1013_zpsvvirmhdi.jpg.html)




And finally, after nearly 5 years of ownership of this car, I finally got to take it home... what a day :)

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/DSC_1017_zpskuzkmxd6.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/DSC_1017_zpskuzkmxd6.jpg.html)

[talkingcars]

I'm liking that.

[carmadbaker]

I love this car :thumbsup:
Love the smoke plumes, no smoke no poke!
Expected hp with new injectors?

[ZS Phil]

Again, thanks for the comments :)

Bit more progress last night with improving boost control... I wont bore everybody with the details (unless anybody wants to know, in which case more than happy to share what I've done).

To answer the question of expected power?
I'm not really sure. I've been so close to 200 that I guess I'll need to break that at some point as a bit of a target.
It feels really good with the current set up and even after that I'm looking into hybridising the cold side so plenty of avenues to explore even with the current turbo.

Bear in mind it has to be a reliable daily too though :P

[p_b82]

You can bore me with the details ;)

interesting how the smoke is still too much with the 200 TDI's & the 2056....

I am really not sure what I going to do about that.... will hopefully have my GTB1856v in later this summer - going SDI hybrids first to get it all bedded in, but due to the soot, I am concerned by the 200TDI's with the VNT mech...

It really sounds like we need something inbetween for nozzle sizes - pity there doesn't seem to be anything else out there with the right angles :(

[ZS Phil]

Since you asked :D

So previously I had been running 25 psi boost with the WG controlled by an external WG specific controller (the black thing in the diagram) which SHUTS at threshold pressure meaning boost pressure can no longer enter the top chamber of the WG however boost pressure still goes to the bottom chamber which pushes against the diaphragm and the gate opens.

This worked fine however because the wastegate spring is only rated to 10 psi and I wanted 25 psi, I was starting to get creep at 18-19 psi. One of the benefits of the screamer pipe is you can hear exactly when the gate starts to open.

Now to overcome this I have tried something which I haven't seen done before... I have added a mechanical boost controller before the lower chamber of the WG.
I have left the original WG controller at 25 psi so boost stops reaching the top chamber at 25 psi still however no boost will be allowed to reach the bottom chamber until 27psi as dictated by the added mechanical boost controller. Peak boost is now 29 psi.

There is now much less creep, the gate is virtually open or closed with absolutely minimal "in between".
This means spool is much quicker and there is less smoke. The extra few psi have transformed the car and really started to help the extra fuel from the 200 tdis get burnt.

I am currently running the fuel pump maxxed out with the landrover nozzles too so there is some smoke as to be expected. I'm going to tweak fuelling down a bit up top but I'm at the stage now where I'm confident the landrover nozzles are a good choice for the correct turbo.

I couldn't be happier with the 2056 now I've made the negligible changes.

Some results from testing:
EMP @ 70 mph cruising = 4psi
EMP during normal but hardish acceleration= 1:1 ratio with boost.
Peak EMP (4th gear foot to the floor 50-90 mph= 38psi @ 29-30psi boost.

All in all, I think that illusive 200 is on the cards for the "masses" without VNT.

http://i276.photobucket.com/albums/kk11/zsphil/POL%2015/WG_zpsjzxrojgh.jpg (http://s276.photobucket.com/user/zsphil/media/POL%2015/WG_zpsjzxrojgh.jpg.html)

[p_b82]

nice results there - and that EMP is nice and 'safe' 36-38PSI is what I think is the limit of what we should be peaking at; as we hit 32PSI on just the SDI's on the standard turbo with a remap;

with my foot limit I did not go beyond 36PSI and I've not done a HG since - so think that is probably the max we want to play with.... just hope that even with the extra flow out the back we do not have too high cylinder pressures!

I had forgotten your map was set up for max fuel on the old SDi's - hence the smoke.... so certainly has potential for 200 on that turbo I'd have thought.

Do you happen to know your EGT's?

[ZS Phil]

nice results there - and that EMP is nice and 'safe' 36-38PSI is what I think is the limit of what we should be peaking at; as we hit 32PSI on just the SDI's on the standard turbo with a remap;

with my foot limit I did not go beyond 36PSI and I've not done a HG since - so think that is probably the max we want to play with.... just hope that even with the extra flow out the back we do not have too high cylinder pressures!

I had forgotten your map was set up for max fuel on the old SDi's - hence the smoke.... so certainly has potential for 200 on that turbo I'd have thought.

Do you happen to know your EGT's?

I don't have an EGT probe unfortunately but another guy in Poland (Remi) has just fitted the same turbo and has reported good figures however he is only running SDIs so probably not a fair comparison.

[ZS Phil]

Just for giggles, a quick video to show that the 200 tdi hybrids can be "acceptable" if driven sensibly even with a hardcore "max fuel" map.
Equally, as the second half shows they can be obscene (but bloody quick and a whole lot of fun).

Turn the speakers up :D https://www.youtube.com/watch?v=Toox_N0T3_Q

[peterzs]

Good vids.

:bow::bow::bow:

[p_b82]

Yeah it won't be a 'valid' comparison as the EGT really does change with soot/smoke levels.... Your smoke looks like mine did on the wingies I had...... and I was hitting 850c with them on sustained full bore runs.... peaked at I think 650 with the SDi hybrids under the same load.....

the scary thing is that fuel is limited in 1st and 2nd due to the torque limiter.... in 3rd and upwards it must be mentally bad lol

Does sound nice tho :D

[ZS Phil]

Yeah it won't be a 'valid' comparison as the EGT really does change with soot/smoke levels.... Your smoke looks like mine did on the wingies I had...... and I was hitting 850c with them on sustained full bore runs.... peaked at I think 650 with the SDi hybrids under the same load.....

the scary thing is that fuel is limited in 1st and 2nd due to the torque limiter.... in 3rd and upwards it must be mentally bad lol

Does sound nice tho :D

As had been said before, I'm convinced from what I've heard about wingies that they are just 200tdi nozzles with the part numbers ground off.
They are the only obvious upgrade from a catalogue browsing point of view in terms of spray angle, orifice size, two stage etc.
Orifice size of the 200tdi is 0.24mm whereas the SDIs are 0.22mm so not a huge difference although the effect this has on area is obviously very significant.

I spent all day yesterday mapping the 200tdis in. The video I posted was just for a laugh, it hasn't stayed like that!


MAPPING ADVICE FOR 200 TDI NOZZLES

First of all, don't bother on a standard turbo, SDIs are more than enough for the job, this only applies for fitting a bigger turbo.

If anybody wants to run 200tdis the best advice I can give is less is more.
I took the "max fuel" map off and replaced it with the original map from my girlfriends 45 (101) with the only differences being the increased rev limit and hard-cut as before. This was the baseline.

Even with the virtually stock map there was smoke under normal acceleration (like in the first clip of the video) although higher up (once on boost) the smoke was much less as to be expected. It felt just as quick top end and EMP dropped (as to be expected).

Back on the driveway and the map edited, I reduced requested fuel in the drivers wish maps by up to -50% for lower throttle position values and gradually increased to standard values for ~50% throttle then added 10% for +70% throttle over 2000 rpm.

I also edited the smoke limit map, by up to -40% below 0.5 bar boost (corrected) gradually increasing to standard values at 0.7 bar then +15% over 1.0 bar.

Out for another test drive... the smoke situation is really good, just like a mapped car on SDIs now but maybe with a bit more on full throttle- this is a haze now rather than James Bond smoke screen- you can get away with full throttle without looking like a complete wally. Performance wise, it feels just as quick full throttle as the "max fuel" map however lower down the pull is much better, maybe due to reduced temps.

Back home for a few more tweaks to make the power delivery more linear and that's where I'm up to.

If anybody says the 200 tdis are too much... I'm sorry but it just isn't suitably mapped.

So, in summary, I'm chuffed the injectors I spent so much money on can be used and further more I have as much fuel to play with as I like when the next stage of turbo inevitably comes.
Also, I've not measured it yet but I bet fuel economy has gone up significantly too given how much fuel I took out of the standard map lower down.
Exciting times :D

[Skillen]

Would have been good to see this vs the track car (before stripping).
When I had RZA it left my cousins 170 Leon 550 diesel in the dirt from standstill and from a rolling 30 start which is the opposite to what I expected with his torque (obviously heavier car though.)
With the gains you've made with the car it'll be interesting to see how it is against one.

[ZS Phil]

Yeh, would make an interesting comparison.
I think from a standing start the 180 would have the diesel, also round a track the 180 would have it simply because of the longer power band.
That said, in-gear acceleration and a twisty b road where the torque will throw you from corner to corner I think the TD could well be the weapon of choice.
They are both fun, having to choose just one would be a tough call.

[Skillen]

I'd go for the 180 but I just can't see myself in a diesel lol.
I can't see myself in a 4pot of any kind tbh!
But I think it'd be funny to smokescreen a young fool thinking he had the diesel car easily!
You need a button that can change the map so you can do the smokescreen for fun ha!

[ZS Phil]

The smoke switch idea would actually be pretty easy to do...

There is a "limp mode" map which it goes into if the MAF sensor signal is lost.

All I'd need would be a switch to lose the MAF signal and to change the "MAF-less map" to request loads of fuel, job done :D

... You've got me thinking now, a dual map might actually be a good idea.

[Skillen]

In the lower dash.
Where the ashtray is.
Press the ashtray, it flips down revealing toggle switches. Labeled "SMOKE" & "BOOST" (both do the same thing but no one needs to know as one switch is boring.)

[p_b82]

Great news that Phil - now to get it on a dyno....

Maybe I will jump to the 200TDI's fairly quickly - I've a low SDI map on mine atm to save the HG on the stage 2.... so will be hugely underfuelled for the GTB1856v.

Smoke levels of just a hazing/SDI equivalent is what we need to really achieve with the VNT as uou know, otherwise it is de clagging of the vanes!

I think when they bring in actual emissions tests - if our derv's get sucked into that, we will need a dual map for sure...

RE the 180 vs tuned diesel.... a stripped track slag would have the advantage regardless, but It would be interesting if they were both the same spec and to compare.

The engine weight is the same, so it would come down to how well you can get the power/torque down and acceleration from corners - if the driver was the same, and the conditions....

[ZS Phil]

In the lower dash.
Where the ashtray is.
Press the ashtray, it flips down revealing toggle switches. Labeled "SMOKE" & "BOOST" (both do the same thing but no one needs to know as one switch is boring.)

Haha I like it!
Slightly off topic but do you think you'll end up coming over for that carpet at some point? Really don't want to throw it away but I need the space in the garage :(

Great news that Phil - now to get it on a dyno....

Maybe I will jump to the 200TDI's fairly quickly - I've a low SDI map on mine atm to save the HG on the stage 2.... so will be hugely underfuelled for the GTB1856v.

Smoke levels of just a hazing/SDI equivalent is what we need to really achieve with the VNT as uou know, otherwise it is de clagging of the vanes!

I think when they bring in actual emissions tests - if our derv's get sucked into that, we will need a dual map for sure...

RE the 180 vs tuned diesel.... a stripped track slag would have the advantage regardless, but It would be interesting if they were both the same spec and to compare.

The engine weight is the same, so it would come down to how well you can get the power/torque down and acceleration from corners - if the driver was the same, and the conditions....

I'm just amazed at how much fuel I've taken out of even the standard map lower down and how hard it pulls still.

You are right though, it needs to go on the rolling road!

Really starting to get back into the diesel tuning... just sent a message to the local turbo place asking about scope for a 2060 hybrid using a 330d cold side and billet compressor... This is meant to be the "sensible" car!!

[ZS Phil]

I decided to take the TD for a bit of a drive recently.

A few stats:

27 days
7546 miles
164 hours behind the wheel
17 countries
76 towns
8 capitals
14 mountain passes
8 car ferries
3 time zones
2 crossings of the arctic circle
2 breakdowns
1 tired old MG

I wont list all the countries or anything (unless anybody wants me to) but as always, I'll just try and tell a quick story with a few words and pictures.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/europe%20route_zpstk4wzdel.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/europe%20route_zpstk4wzdel.jpg.html)





Before we set off...

I only decided to take the ZS over the 45 at the last minute. The 45 would probably have been the "sensible" choice (still running 160 bhp spec) but I wanted some pics of the ZS on some of "the worlds best driving roads"... sad but true.

Preparations 2 days before we set off were to raise the suspension 20mm up front and 12mm at the rear (was a bit nose down before), replace the 2 front Conti Sport Contact 3's for some new ones, replace a leaking oil pressure switch, replace the aux belt and tensioner and give it a good service.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1626_zpsxoj848la.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1626_zpsxoj848la.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1622_zpsjlwkmvml.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1622_zpsjlwkmvml.jpg.html)


Set off after work and drove down to Dover that night

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1632_zpsohymtant.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1632_zpsohymtant.jpg.html)

The ZS blends in surprisingly well considering the decals on the roof... waiting for the ferry.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1633_zpsj3yxribf.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1633_zpsj3yxribf.jpg.html)


Now then, we saw so many places that it was impossible to take a pic of the car everywhere but some of the scenic places it was rude no to so below are a few of my faves from the trip in the order they were taken.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1642_zpsgpfbujcs.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1642_zpsgpfbujcs.jpg.html)


This one was taken at 11pm in Norway- 24 hours of daylight.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1648_zpsnzmtktqk.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1648_zpsnzmtktqk.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1655_zps5fxutlab.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1655_zps5fxutlab.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1658_zps5a9g8trc.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1658_zps5a9g8trc.jpg.html)



See those toy boats at the bottom of the bath tub??

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1663_zpsvcgsdvsc.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1663_zpsvcgsdvsc.jpg.html)


Well this is what they look like!

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1665_zpso9gocjxb.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1665_zpso9gocjxb.jpg.html)


http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1680_zpsfviygjrh.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1680_zpsfviygjrh.jpg.html)


http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1683_zpsqc8vnzrl.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1683_zpsqc8vnzrl.jpg.html)


The "Arctic Road" Norway.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1685_zpsz47qiumd.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1685_zpsz47qiumd.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1689_zpsk9w5kgus.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1689_zpsk9w5kgus.jpg.html)


Naturally saw lots of reindeer as we were approaching Lapland

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1699_zpsmus7eueb.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1699_zpsmus7eueb.jpg.html)


I wonder how many ZS's have been in the arctic circle?

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1703_zpswayrej8g.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1703_zpswayrej8g.jpg.html)


I didn't get any more car pics until Austria when this happened about 5,000 miles into our trip.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1749_zpstsj5wxh9.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1749_zpstsj5wxh9.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1747_zpsx6tqmhhi.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1747_zpsx6tqmhhi.jpg.html)


Coolant pipe had worn through. Noticed the temp gauge as it was about 3/4 to max so pulled over straight away and coolant was still dripping so caught it just in time.

Repaired at the side of the motorway by shortening the pipe and re-organising some other pipes.

I did have 2l of spare coolant but that wasn't enough so the rest was substituted for ice tea!


This happened just before we started the big passes. Didn't stop us though.

Grossglockner:

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1751_zps2c7ftxhr.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1751_zps2c7ftxhr.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1756_zpsovqztw5m.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1756_zpsovqztw5m.jpg.html)


She was getting a bit warm so whipped the plate off.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1758_zpsejems47o.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1758_zpsejems47o.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1761_zpssirovcfa.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1761_zpssirovcfa.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1766_zpsyy0jjpin.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1766_zpsyy0jjpin.jpg.html)



Mid holiday bath.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1783_zpspzjawjk6.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1783_zpspzjawjk6.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1792_zpspvzyizhm.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1792_zpspvzyizhm.jpg.html)


Next pass= Hantennjoch

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1796_zpsfq1rp9y1.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1796_zpsfq1rp9y1.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1797_zpsz2mmuo0c.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1797_zpsz2mmuo0c.jpg.html)


Then onto the famous one... the mighty Stelvio and all 48 of it's hairpins.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1803_zpsgjleamch.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1803_zpsgjleamch.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1810_zpsscsv7lub.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1810_zpsscsv7lub.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1818_zpslmmw9bd5.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1818_zpslmmw9bd5.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1824_zps9wfx8pxa.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1824_zps9wfx8pxa.jpg.html)

[ZS Phil]

NEXT

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1833_zpstidzsfjr.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1833_zpstidzsfjr.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1832_zps50uhmesp.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1832_zps50uhmesp.jpg.html)

NEXT

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1840_zpssoxfwgrt.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1840_zpssoxfwgrt.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1837_zpstgqtreog.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1837_zpstgqtreog.jpg.html)

NEXT

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1851_zpsytckhv61.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1851_zpsytckhv61.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1844_zpsvpwqmpsj.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1844_zpsvpwqmpsj.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1845_zpsw8txgwuc.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1845_zpsw8txgwuc.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1854_zpszwnjg1ru.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1854_zpszwnjg1ru.jpg.html)


NEXT

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1860_zpsexl3vqhv.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1860_zpsexl3vqhv.jpg.html)

NEXT

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1865_zpsibiv0kav.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1865_zpsibiv0kav.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1863_zpssyxbpqw8.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1863_zpssyxbpqw8.jpg.html)

Dont fall off!

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1864_zpsm7zc1t35.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1864_zpsm7zc1t35.jpg.html)










So we just finished the last of our big passes and pop goes the clutch master cylinder in Switzerland.

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1866_zps7tnutyvj.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1866_zps7tnutyvj.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1867_zpsyumrfghn.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1867_zpsyumrfghn.jpg.html)


No parts available at all (not even in left hand drive) so had to source my own. Made sense to upgrade the complete system so got Dark ice to send me the diesel "Sheddist" kit over next day.
Really can't fault their service, they really helped me out.

In the mean time, the Skoda of death!

http://i276.photobucket.com/albums/kk11/zsphil/TD%20Euro%20trip/DSC_1869_zpsbqc7ctaf.jpg (http://s276.photobucket.com/user/zsphil/media/TD%20Euro%20trip/DSC_1869_zpsbqc7ctaf.jpg.html)


Got the MG back on the Friday at lunch time and our boat home set sail from Dunkirk on the Saturday morning at 8 am.

The mechanic was really nice and the garage was an old MG Rover dealer so he knew what he was doing however he accidentally knocked my mechanical boost controller and cracked the plastic. This meant driving from Switzerland to Blackpool with only 10 psi boost when the map is for 29psi boost... it was smokey.

Always one to make the most of a bad situation, I've just finished fitting a Greddy Profec electronic boost controller but that's a story for another day :)

[jc600]

Awesome!!!! :D

Think I might have to plan something like this one day. :)

[peterzs]

Wow, road trip to end all road trips.

Great story and great pics.

Wish I had the guts to do it, even the planning would put me off.

Glad the car went well, just shows how good they are. Didnt look out of place anywhere.

:hooray::hooray::hooray: :thumbsup::thumbsup::thumbsup:

[p_b82]

I saw it on FB, but these extra pics are mighty :)

And I thought my road trip to Norway* was going to be adventurous.... although granted mine is currently still at risk of HG blowing lol

I didn't get to the post office - but got a box ready for the injectors, so will get them sent Monday AM hopefully...

Epic trip though - rather Jealous :D

*Won't be happeneing now as friend I was going to visit is moving back to Sweden

[talkingcars]

Not jelous at all - you need to name the countries or you didn't go there!

What sort of accomodation were you using?
Did you book it beforehand?

Your stats make our euro road trips in the F look pathetic, but we can only get 2 weeks off work at one time so it becomes a bit restrictive and this year was the first time we've gone for 2 weeks.

I think the closest we've come stat wise was
7 days
3500 miles
8 countries
13 border crossings
1 largest bridge in europe
1 longest tunnel in the Alps
3 laps of F1 circuit (Monaco 2 weeks after so all the barriers were still up).

This year we had more time so drove to Naples and stayed there for a week.

My advice to anyone who fancies a euro road trip - do it.

[ZS Phil]

Awesome!!!! :D

Think I might have to plan something like this one day. :)

Do it! As the MG slogan goes, "life's too short not too".

Glad we did it but could do with a holiday to recover from it.


Wow, road trip to end all road trips.

Great story and great pics.

Wish I had the guts to do it, even the planning would put me off.

Glad the car went well, just shows how good they are. Didnt look out of place anywhere.

:hooray::hooray::hooray: :thumbsup::thumbsup::thumbsup:

Cheers Peter :).

Yeh, the car did well considering its age and mileage. A chaffed pipe and a master cylinder could go on any make or model of this age.



I saw it on FB, but these extra pics are mighty :)

And I thought my road trip to Norway* was going to be adventurous.... although granted mine is currently still at risk of HG blowing lol

I didn't get to the post office - but got a box ready for the injectors, so will get them sent Monday AM hopefully...

Epic trip though - rather Jealous :D

*Won't be happeneing now as friend I was going to visit is moving back to Sweden

When you go to Norway, whatever you do, make sure you do "Path of the trolls" it was probably my fave part of the whole trip. Absolutely stunning. Geiranger is a must.

No rush with the injectors, the ZS needs to come off the road for a bit, I'm not quite happy with it at the minute to such an extent I'm looking at another "sensible" car whereby the 2 ZS's will be toys.

It needs bushes, brakes, a ball joint, indicators fixing, coilovers re-furbing and a bit of paint which the Swiss jet wash removed for me!
A gasket between the wastegate and manifold has just gone while I was setting up my new boost controller too.
All I'm saying is I wont be in a position to put your injectors in straight away I'm afraid. All these problems have become apparent literally in the last couple of days :(

[ZS Phil]

Not jelous at all - you need to name the countries or you didn't go there!

What sort of accomodation were you using?
Did you book it beforehand?

Your stats make our euro road trips in the F look pathetic, but we can only get 2 weeks off work at one time so it becomes a bit restrictive and this year was the first time we've gone for 2 weeks.

I think the closest we've come stat wise was
7 days
3500 miles
8 countries
13 border crossings
1 largest bridge in europe
1 longest tunnel in the Alps
3 laps of F1 circuit (Monaco 2 weeks after so all the barriers were still up).

This year we had more time so drove to Naples and stayed there for a week.

My advice to anyone who fancies a euro road trip - do it.

Your stats sound pretty much the same as ours if you double them- we were away for double the time though. Your trip sounds really good too.
I just re-read your post. 3500 miles in SEVEN days! Makes us look like we were messing about.

OK, since you asked!

1. England
2. France
3. Belgium
4. Netherlands
5. Germany
6. Denmark
7. Sweden
8. Norway
9. Finland (and Lapland)
10. Estonia
11. Latvia
12. Lithuania
13. Poland
14. Slovakia
15. Austria
16. Switzerland
17. Italy
Then back up through France.

We just took camping gear for when it was nice weather, if it rained we went on booking.com and found the cheapest place we could in a given area.

Nothing was pre booked other than the ferry crossings.

[talkingcars]

We just took camping gear for when it was nice weather, if it rained we went on booking.com and found the cheapest place we could in a given area.

Nothing was pre booked other than the ferry crossings.

As we do the euro trips in the MGF* we don't have room for camping gear, and Mrs TC hates camping so it's hotels all the way for us.

We have done the UK without prebooking but we're not brave enough to do this in Europe.

*except going to see the mother in law and of course we stay in her appartment.

[talkingcars]

Just shown Mrs TC this and she's asking what the weather was like on the northen part of the trip, i.e. Norway/Sweden/Finland (although she wants to see the northan lights which of course are not visible at this time of the year).

[ZS Phil]

Yeh, we really want to go back for the Northern lights... the price to pay for the 24 hour sunlight.
The weather in the Scandinavian countries was ok. Obviously it depends how far up you go as to how cold it will be but we just crossed into the arctic circle and went to the Santa Claus village. That is where the pic of the arctic circle sign was taken and you can see what Nadia was wearing. Probably about 13-15 degrees at a guess.
When we did the highest point of the "Path of the trolls" it was a bit cooler up there as you can see from the depth of the snow.

If you want to do the northern lights, the main "town" next to Santa Claus village is supposed to be a good place. There is a big glass viewing tunnel or a big hill (which is supposedly mosquito infested). The town is called Rovaniemi.

If you pre-book there are plenty of deals to be had with little wooden cabins which are basic but really well kept and clean. Suppose it's just a step up from camping.

[p_b82]

When you go to Norway, whatever you do, make sure you do "Path of the trolls" it was probably my fave part of the whole trip. Absolutely stunning. Geiranger is a must.

No rush with the injectors, the ZS needs to come off the road for a bit, I'm not quite happy with it at the minute to such an extent I'm looking at another "sensible" car whereby the 2 ZS's will be toys.

It needs bushes, brakes, a ball joint, indicators fixing, coilovers re-furbing and a bit of paint which the Swiss jet wash removed for me!
A gasket between the wastegate and manifold has just gone while I was setting up my new boost controller too.
All I'm saying is I wont be in a position to put your injectors in straight away I'm afraid. All these problems have become apparent literally in the last couple of days :(

I've been swamped with work all day so not been able to get out yet either - I've got the injectors boxed, but will keep hold of them until you are in a position to test it. It might be that I am ready to try again sooner than you, so saves us a bit of postage.

ping me on FB or here once you are in a position to swap em in I reckon will be the best bet.

I think mine needs a new IC hose - it is looking like boost leak is not a long time away from happening - and where it is, will be a bumper off job I reckon!

The 'joys' of project cars :laugh:

[ZS Phil]

I've been swamped with work all day so not been able to get out yet either - I've got the injectors boxed, but will keep hold of them until you are in a position to test it. It might be that I am ready to try again sooner than you, so saves us a bit of postage.

ping me on FB or here once you are in a position to swap em in I reckon will be the best bet.

I think mine needs a new IC hose - it is looking like boost leak is not a long time away from happening - and where it is, will be a bumper off job I reckon!

The 'joys' of project cars :laugh:

To be honest, I think that is a good idea. Don't want you to send them under false hope of what I'll have chance to do with them in the near future.

All sorts of ideas at the moment about which way I'm going to take the car now I'll have the luxury of it being a second car. Some of which are pretty naughty but we'll see.

Hope you get the boost leak sorted :)

[ZS Phil]

It's been 4 years since I updated this thread!
Upon our return from the road trip in 2015 I thought there were a few "niggles" to sort with the car. A proper strip down revealed a bit more work than that was needed! So much so in fact that the sensible thing to do would have been to scrap it. Being a sentimental old fool, that was never going to happen.
So, after lots and lots of work (which I will try to document with pictures at some point), 4 years later she was back in action.
I've done less than 100 miles in her since the full rebuild but just had to get her on the dyno.

On well used SDI injectors and a "max fuel" map she pulled a healthy 203HP / 373Nm.

Can update the spec list if needed.

[Dan1971]

.....

On well used SDI injectors and a "max fuel" map she pulled a healthy 203HP / 373Nm.

Can update the spec list if needed.

:bow:

[talkingcars]

Upon our return from the road trip in 2015 I thought there were a few "niggles" to sort with the car..

Sounds like me and my MGF - we returned from Rome in June 2016 needing to replace a holed wishbone, 3 years later, a scraped TF and more money than the car is really worth and she is now back on the road supported on TF running gear.

[p_b82]

I'm sure there must be more to the rebuild than just maxing out the mapping side, I'm not aware of many people who'd been able to get more than 180bhp out of SDI's...

So you've either found a hidden thing no-one else has, or you've done something sneaky :D

still 200bhp and 275lbsft must be a nice drive!

[ZS Phil]

I'm sure there must be more to the rebuild than just maxing out the mapping side, I'm not aware of many people who'd been able to get more than 180bhp out of SDI's...

So you've either found a hidden thing no-one else has, or you've done something sneaky :D

still 200bhp and 275lbsft must be a nice drive!

The map is still the same as when I was running SDIs with the 2056s turbo which would have given 180 bhp at the very best.
Its now got a really healthy low mileage engine and fuel pump and the turbo has been hybridised into a 2060.
I think the SDIs have more potential than people give them credit for as long as the gas can get out!
With the standard 2056s turbo at 30 psi, EMP was about 45 psi I seem to remember (it was a good while ago now!). With the latest turbo at 30 psi, EMP spikes at 28 psi. 38mm external waste gate is helping massively with this as well as a decent 60mm billet compressor wheel.
I'll have to find a way of getting the graph up, it's a really nice curve.
Did you ever get yours back on the road? You were going vnt I seem to remember, did anything ever come of the controllers in the end?

[ZS Phil]

Sounds like me and my MGF - we returned from Rome in June 2016 needing to replace a holed wishbone, 3 years later, a scraped TF and more money than the car is really worth and she is now back on the road supported on TF running gear.

At least you got an upgrade out of it! I just bury my head in the sand when it comes to money spent vs what these cars are worth. Logic doesn't come into the equation anymore haha.

[p_b82]

The map is still the same as when I was running SDIs with the 2056s turbo which would have given 180 bhp at the very best.
Its now got a really healthy low mileage engine and fuel pump and the turbo has been hybridised into a 2060.
I think the SDIs have more potential than people give them credit for as long as the gas can get out!
With the standard 2056s turbo at 30 psi, EMP was about 45 psi I seem to remember (it was a good while ago now!). With the latest turbo at 30 psi, EMP spikes at 28 psi. 38mm external waste gate is helping massively with this as well as a decent 60mm billet compressor wheel.
I'll have to find a way of getting the graph up, it's a really nice curve.
Did you ever get yours back on the road? You were going vnt I seem to remember, did anything ever come of the controllers in the end?

Interesting - a lot of people have stuck bigger turbo's on, but really struggled to break 180-190 with SDI's regardless of the turbo used.
Guess the existing manifold is a big issue.... I did think about looping in a "blow off" pipe to divert some exhaust gas while I was running the tiny hybrid, but felt the control of it to not loose too much boost was going to be an issue....
Going "big" on the exhaust side with an external waste gate solves that one tho :D

Bit of a long story with mine, but it's off the road currently, all the parts are plumbed in; controller included, though my car required a complete re-evaluation of the approach due to a very dirty signal for some of the critical sensors...(without those working properly, no decent vane control) plus a few physical issues with the exhaust manifold and turbo...

But we're getting much closer so shouldn't be too much longer now.

[ZS Phil]

Yeh, I had the same issue with my VNT, only managed 170ish I think with SDIs, never had it on the dyno with SDIs and the 2056s but it didn't feel any quicker with the SDIs in but at least it didn't keep sooting up a vnt mech!
With 200tdis and the vnt (1852) with loads of smoke it did 198bhp but that was with high EMPs and Kris did something to the rollers to encourage the boost to build (added more resistance somehow). With the rolling road in its normal setting it only managed 180 because the boost wouldn't build in the same way as it did on the road... The joys of vnt control as it sounds like you are discovering. I'm sure you'll get there though, would be interesting to do a rolling road session together and compare notes once it's in that position.
Next step for me is more fuel, going back to experiment with 300tdis which are on the shelf, just need to get them set up with higher opening points. Not sure how well they will work but still not found anywhere that can hone the standard/SDI nozzles which would be my preferred choice.

As a side note, how are we uploading photos these days?

[p_b82]

Yeah - it was a case of "do we continue to persevere with these issues, or just take that step back and generate our own signal" ... we've done the latter, and things are looking up.

I'll hopefully have some figures of it on SDI's and then the custom injectors - as you say clean burn is more critical with VNT, so hopefully we get some good figures that don't require de-coking every 200 miles :D
the comparison of the curves will be interesting, I've always been worried that bigger units is pushing boost/torque too high up the range for every-day driving.

I use google photos; you can share the direct link in img tags if you open the "long link" by viewing the image itself.
Others I think use one of the apps that enables photos to be attached using that, but I can't comment on it.

[ZS Phil]

Yeah - it was a case of "do we continue to persevere with these issues, or just take that step back and generate our own signal" ... we've done the latter, and things are looking up.

I'll hopefully have some figures of it on SDI's and then the custom injectors - as you say clean burn is more critical with VNT, so hopefully we get some good figures that don't require de-coking every 200 miles :D
the comparison of the curves will be interesting, I've always been worried that bigger units is pushing boost/torque too high up the range for every-day driving.

I use google photos; you can share the direct link in img tags if you open the "long link" by viewing the image itself.
Others I think use one of the apps that enables photos to be attached using that, but I can't comment on it.

Thanks for the tip regarding the photos, had a play and think I've managed to link one picture... the most important one!
You're right regarding bigger units pushing the curve to the right but I suppose when the power does come on its more linear than a smaller unit which can give almost a bell shaped curve as it runs out of puff higher up. Swings and roundabouts I guess.
Cant wait to try some different injectors. Got some new nozzles in the garage to try, just need to get them set up with raised opening pressures. If you still want yours testing (you mentioned it a few years ago) Id be happy to, although I guess you're not far off testing them yourself from the sounds of things!
https://lh3.googleusercontent.com/Q6I3DNNtmkMEWSyJ0UHBSxT-lDMOYUYuBoyFue5cGYg7ibKal1tVBi2xmHmF-_se-9DkTsAAjwis7jOXxTE1zMbu4Vq6dtJSRps_Z0dVWjPusapsoSe OY0CapRBvXFW3ho_Ntohq9g=w493-h657-no

[p_b82]

You're still over stock peak torque at 2400 rpm - but given that you've only got a 1200 rpm band of peak torque/power by the look of it, it makes that sweet spot smallish.

That said, if you're not giving it full beans you're not going to notice that in real world with the extra torque that you do have on tap. so looks good :)

We're looking at peak torque around the 2k mark - inline with the crappy stage 2's; with the aim to hold it flat until 4k (might not be possible but that's the aim), maybe 4200.. but unfortunately our head design just doesn't make sense to tune it up to the 5500 limit as you can see it just runs out of puff.

RE the offer of testing, I think at this point we're close ourselves so I'll pass; I'm happy that they flow enough fuel as I fitted them previously, the issue will be what the combustion is like...

There are more nozzles that can be tried in the catalogue than there were a couple of years back, so if they don't work, I may well fire these ones your way (not having the soot aspect to content with) if we end up doing some trial and error. If you're interested in experimenting that is.

[ZS Phil]

Always up for a bit of trial and error so just keep me posted. Last week I dropped off some spare injectors and new bigger nozzles to a local specialist to rebuild/ balance and most importantly play with the opening pressures. We'll then see what happens.
Regarding the graph I can see what you mean from how it looks but actually (and I agree it's a very personal/subjective thing this), having come from naturally aspirated petrol engines which all like to be thrashed to make progress (cammed v6 race car, v8 ZTT and recently added vx220), I actually like the linear power curve. There is something satisfying about building the revs and the more you work it the more power you get. My hardcut is set to kick in between 4800 and 4900 but you can see from the graph there is still over 190bhp at the limiter. Also, the fact that power and torque gradually build puts less stress on the drive train.
That said, a huge lump of low down torque does make the car feel "muscular" and with a vnt, assuming it can be properly controlled, I guess you can hopefully make it cling on to the top end too and have best of both worlds.
My 330d always felt like that, a low down hit but still pulled and pulled up to the top.
Hopefully you'll make it to POL or similar at some point as I'd love to see how they drive differently.

[p_b82]

Tbh - I think the aim is to be looking at about the same sort of torque peak as you've got, just starting a bit earlier in the range.
Like you, I've got a bit of awareness of mechanical sympathy; but we'll se what the pressures are all looking like as well as smoke/soot levels etc.

venturing into the unknown, but the test bed runs all suggest it'll spool like a 15 and is an 17/18 hybrid so should also give me more up top.

It is not going to pull as hard as the mustang regardless what I do, less torque & fewer revs; but I think it will corner better and be more "real world usable" with the power/torque it will have.

As you say it is all subjective & once it's on the road more than happy to meet up, hoping to make more events when it's allowed on the road again!
Worst case mini meet half way one time!

[gAZ]

It's been 4 years since I updated this thread!
Upon our return from the road trip in 2015 I thought there were a few "niggles" to sort with the car. A proper strip down revealed a bit more work than that was needed! So much so in fact that the sensible thing to do would have been to scrap it. Being a sentimental old fool, that was never going to happen.
So, after lots and lots of work (which I will try to document with pictures at some point), 4 years later she was back in action.
I've done less than 100 miles in her since the full rebuild but just had to get her on the dyno.

On well used SDI injectors and a "max fuel" map she pulled a healthy 203HP / 373Nm.

Can update the spec list if needed.

:trampoline: 200+ bhp L series?

Wouldn't mind seeing the complete spec list for those mods that got you those gains? + price of parts.

:trampoline:

[peterzs]

still loving my derv

158 and 238 but goes like a train.

great cars.

ZS Feels more planted than my 160 TF AND I HAVE NEVER HAD A TWITCHY moment going fast round a bend. Not like the TF where I have to keep my foot down to keep it balanced.

[gAZ]

still loving my derv

158 and 238 but goes like a train.

great cars.

ZS Feels more planted than my 160 TF AND I HAVE NEVER HAD A TWITCHY moment going fast round a bend. Not like the TF where I have to keep my foot down to keep it balanced.

I agree.. They do handle exceptionally well for a 15 year old car! :bow:

Although their 'refinement' especially at lower speeds does leave a little to be desired. :horse:

I'd say I love my mk1 ZT190 a lot more overall but when pressing on and taking twistys , the ZS TD feels far more fun and rewarding than the big ZT190 .

As a track car, I bet the ZS is a real hoot to race on track!.. Just wish it felt more like the ZT in all the other areas . :)

[peterzs]

:):):)